Replacement Webasto Diesel Heater ECU Controller - Part 2 - assembled and running no ecu

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So far so good. All the parts so far are joined together and even make smoke.
Two MOSFETs died in the making of this video.
The plan is to have a controller everyone can make requiring no programming and using parts readily available and replaceable.
555 Modules - amzn.to/3yr8est
Resistors - amzn.to/3OIX9Z6
Diodes - amzn.to/3NmhJgV
MOSFETs - amzn.to/3OPh2gW
Switch - amzn.to/3xYAxwU
Connectors - amzn.to/3A67fiF
Thank you to Andrew again for making my ideas a reality.

Опубликовано:

7 сен 2024

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Комментарии : 31

@ymmvmeuk 2 года назад

Electrolytic capacitor (with a resistor across it) in series to cool the pump down. Put a diode on the glow plug, too, as the element is often a coil, too, so can generate back-emf. Thank you, very interesting!

@duncanmillward9570 2 года назад

The return of the orange sleeve, normality has resumed. 😅

@twocvbloke 2 года назад

To solve the pump pulsing is to change the capacitors, I've farted about with 555 ICs (not the modules, but just the ICs alone) and changing the capacitors can change the On-Off times, as they're holding the charge to keep the output(s) turned on and the resistors, which I guess are in the form of trimpots there, are discharging them at a set rate, so, lower capcitance, less On-time, or something, I only fiddled with them as timers to operate relays akin to indicator flasher cans... :P

@__WJK__ 2 года назад

Someone call Guinness because I think a record has been broken here. If ever there was a labor of love, this gets my vote!

@assassinlexx1993 2 года назад

Don't you hate it when the magic blue smoke comes out. Clever engineering grouping everything. Better thinking with a beer in hand.

@888johnmac 2 года назад

a moment silence for the MOSFETS that let out the grey smoke so that more expensive components could live .. thank you , now crack on

@hunter00047 Год назад

Just parallel up two mosfets to increase the current capacity.

@Ofca_PL Год назад

Very good video

@thisnthat3530 2 года назад

Assuming it's wired "normally" for astable operation, there should be a resistor from + to pin 7 of the 555 IC, then another between pins 7 and 6. You can alter the on:off ratio by changing these. If your + to pin 7 resistor is 1 tenth the value of the other you'll get about a 10x on:off ratio. Changing the combined total resistance will alter the overall switching frequency (can be corrected by altering the capacitor between pin 6 and - if needed). If the output is "on" for the long period, just invert it with a transistor. This will allow setting the proper duty cycle for the pump.

@wonyankeesays5661 2 года назад

THANKS FOR ALL THE GREAT INFO !

@eby6114 2 года назад

Thanks

@niallcrosbie7491 2 года назад

You sir, are a treasure

@aaronhunter7026 2 года назад

Did the glow plug survive? It looked like it was also smoking while the MOSFET was cooking?

@DavidMcLuckie 2 года назад

Something I'll have to check for next time.

@holeshot406 2 года назад

Good day David. Greeting from Alberta, Canada. Have found your videos enjoyable and helpful. Thank you. I have a gasoline fired eberspacher air heater that I shipped across Canada to have tested, confirming the ECU crapped itself. I am hoping you have a suggestion for a replacement kit I can solder together, or could we still use the original ECU, but make an add on kit to fire the igniter ? Then once lit, the ECU monitors and shuts down as it should ? Fuel pump and circuit we’re working properly, I believe it went through start up procedure, but would fail to ignite the fuel, or petrol as I believe you call in on your part of the world. Thanks in advance, Henry

@DavidMcLuckie 2 года назад

Sadly I haven't played with either Eberspachers or anything gasoline (petrol) related.

@polesworthmace 2 года назад

I suspect that MOSFET is operating in its linear region it's probably not switching off fully

@rljzathras 2 года назад

Agreed. Using the diodes is preventing the 555 driving the gate low quickly. The pull down will be slow to act, and hence allow the linear region to persist for too long.

@demil3618 2 года назад

How about using automotive indicator relays to pulse the pump? Adjust the frequency via the output resistance (like some bulbs out and then it pulses faster).

@hunter00047 2 года назад

Connect 3 mosfets in parallel with larger heatsink will do it👍

@marksweep1970 2 года назад

Well done

@David_11111 2 года назад

yay

@mpelectricalandplumb Год назад

That looks great mate but I don’t think it’s for me looks way too complicated. I purchased a Touran thermo top and it’s a nightmare I’ve cleaned it and got a secondhand water pump as it turned up burnt out and had no fuel pump so I’ve got secondhand ones coming but don’t know if even that will work. I’ve got a w-bus coming not sure if that will control it even I’m a real novice and it’s costing me a fortune. Question please- have you ever removed the diesel solenoid well I did against the recommendations and damaged the gasket 😢 x2 and the copper one was already a bit poor. Any idea where to buy a kit I can’t find anywhere. Cheers Mark

@DavidMcLuckie Год назад

None of the Webastos I've had were the ones with the solenoid. Depending which Webasto board or where it came will be whether or not the W-BUS works. Thermotop V are most likely to work with the W-BUS adaptor.

@danielmusat597 Год назад

In my opinion you missed a step in starting the heater: the glow plug should run with no fuel at all for some time, in order to heat up the start-up chamber. Did you think to use a chinese controller for this device? It is already made and needs only some small tweaks to work. Cheers!

@DavidMcLuckie Год назад

That's not how the original webasto starts. It pumps fuel in, starts glowing, starts air and then pumps fuel. You're thinking of how the air heater starts. Have you done any of the small tweaks to make one work? I haven't seen a video of anyone doing it yet, and I'd like to see it.

@danielmusat597 Год назад

@@DavidMcLuckie My bad. I never played with a webasto and didn't notice this detail. Yes, I thought about chinese diesel heaters when I left the comment. And my thought process was that the pre-heat chamber should be heated up thoroughly before starting fuel pump. Considering that a webasto has a glow plug rated at a smaller power than a chinese one, I thought it would be wise to do so. My diesel heater heats up the even the exhaust pipe before starting fuel delivery. Seems like webasto works in a different way. Perhaps the smaller burning chamber makes the difference. About the chinese controller, it was just an idea. I don't have the funds to do this experiment. However, the tweaks I thought about would be changing the glow plug and the temperature sensor on a webasto with the chinese counterparts. It might work. Cheers!

@DavidMcLuckie Год назад

Ah ok. I did have a commenter say they had converted the chinese ecu to run a webasto but have never actually seen it work. The problem is the chinese ecu having a fan speed sensor and the webasto doesn't.

@danielmusat597 Год назад

@@DavidMcLuckie I think that can be done somehow. After all it is just a magnet and a Hall sensor. I don't know the guts of these deices but anything can be done from an engineering point of view. Depends on how much it costs and the machinery necessary to do it. Cheers!